Waterproof glove and method of making

ABSTRACT

A glove, comprising an innermost liner comprising a first knitted material of a first knit gauge, an intermediate liner disposed over a first outside surface of the innermost liner, the intermediate liner comprising a second knitted material of a second knit gauge wherein the first knit gauge is different from the second knit gauge, a protective layer disposed over a second outside surface of the intermediate liner and an outer layer disposed over a third outside surface of the protective layer.

BACKGROUND

Gloves can be used to protect hands from physical injury, contamination, wet conditions or chemical spills. Conventional waterproof work gloves tend to be uncomfortable because they are inflexible, rough, uncomfortable to wear and do not breathe, trapping moisture inside and causing the wearer's hands to become slippery. Waterproof work gloves may lack texture sufficient for a wearer to effectively grip objects. Further, waterproof work gloves tend to transfer heat and thermoregulate poorly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a depicts an example of a cutaway view of multi-layer glove.

FIG. 1 b depicts an example of a side profile view of multi-layer glove.

FIG. 2 depicts an example of a palm view of a multi-layer glove.

FIG. 3 depicts an example of a backside view of a multi-layer glove.

FIG. 4 depicts an example of a process for making a multi-layer glove.

FIG. 5 depicts an example of a process for making a multi-layer glove.

FIG. 6 depicts an example of a process for making a multi-layer glove.

DETAILED DESCRIPTION

Several examples of the present application will now be described with reference to the accompanying drawings. Various other examples of the disclosed multi-layer garment are also possible and practical. The disclosed multi-layer garment may be exemplified in many different forms and should not be construed as being limited to the examples set forth herein. For example, the multi-layer garment may comprise a sock, a hat, pants, a shirt, a coat and or other garment and claimed subject matter is not limited in this regard.

The figures listed above illustrate various examples of the disclosed technology and the operation of such examples. In the figures, the size of the various elements is not intended to represent the size of the various physical components nor are the shading or patterns intended to represent the materials, knit or weave patterns and/or other physical properties. Only those parts of the various units are shown and described which are necessary to convey an understanding of the examples to those skilled in the art.

FIG. 1 depicts an example of a waterproof glove 100 comprising multiple layers. Glove 100 may comprise an innermost liner 102, an intermediate liner 104, a protective layer 106, and an outer layer 108.

In an example, innermost liner 102 may comprise a first knitted cloth 110. First knitted cloth 110 may comprise a terry cloth knit and/or any other appropriate knit. First knitted cloth 110 may comprise a knit of a first particular gauge, for example, within a range of 7-10 GG (B). First knitted cloth 110 may comprise fibers of one or more of the following manmade or synthetic materials: cotton, nylon, elastane, neoprene, polyester, hair, fur, silk, acrylic, rayon, acetate, olefin, wool and/or the like.

In an example, intermediate liner 104 may comprise a second knitted or woven cloth 112. Second cloth 112 may have a knit of a second particular gauge for example within the range of 13-18 GG (B). Second cloth 112 may comprise fibers of one or more of the following manmade or synthetic materials: cotton, nylon, elastane, neoprene, acrylic, polyester, hair, fur, silk, rayon, acetate, olefin, wool and/or the like.

In an example, the first particular gauge and the second particular gauge may be different , e.g., the first particular gauge may be 7 gauge (7 GG (B)) and the second particular gauge may be 15 gauge (15 GG (B)). In another example, the first particular gauge may be 10 gauge (10 GG (B)) and the second particular gauge may be 18 gauge (18 GG (B)). In another example, the first particular gauge may be 15 gauge (15 GG (B)) and the second particular gauge may be 7 gauge (7 GG (B)). In another example, the gauges may be the same, e.g., the first particular gauge may be 15 gauge (15 GG (B)) and the second particular gauge may be 15 gauge (15 GG (B)).

In an example, a first surface 114 and/or a second surface 118 of innermost liner 102 may be brushed, knapped and/or otherwise loosened or frayed.

In an example, protective layer 106 may provide glove 100 with water resistant, waterproof and/or puncture resistant properties. Protective layer 106 may be disposed over an entire outer surface 116 of intermediate liner 104. In another example, protective layer 106 may be disposed over only a portion of outer surface 116 of intermediate liner 104. Protective layer 106 may comprise one or more of the following: vinyl, polyvinyl chloride (PVC), nitrile, nitrile, foamed nitrile, rubber, neoprene, polyurethane and/or the like and may provide glove 100 with water resistant, waterproof and/or puncture resistant properties.

In an example, outer layer 108 may be disposed over an outside surface 120 of protective layer 106. Outer layer 108 may comprise any material suitable for improving wet and/or dry gripping properties of glove 100. For example, outer layer 108 may comprise one or more of: a sandy nitrile polymer, a foamed nitrile polymer, rubber, polyurethane and/or the like. Outer layer 108 may comprise any other appropriate component, compound and/or additive to improve grip, puncture resistance and/or water resistance. In another example, outer layer 108 may comprise embossing, acid finishing, adding polyvinylchloride dots and/or the like.

FIG. 2 depicts an example of a palm view of a waterproof glove 200 comprising multiple layers. Glove 200 may comprise an innermost liner 202 (shown in cutaway view), an intermediate liner 204, a protective layer 206, and an outer layer 208.

In an example, innermost liner 202 may comprise a 10 gauge knitted terry cloth and intermediate liner 204 may comprise a 15 gauge nylon knit liner. Protective layer 206 may be disposed over a portion of an outside surface 214 of intermediate liner 204. In one example, protective layer 206 may comprise a smooth (unadulterated) nitrile polymer. Outer layer 208 may be disposed over a portion of an outside surface 220 of protective layer 206 and may comprise a sandy nitrile polymer suitable for improving wet and/or dry gripping properties of glove 200. Helps with puncture resistance and acts as a waterproof barrier.

FIG. 3 depicts an example of a backside view of waterproof glove 200 comprising multiple layers. Outer layer 206 may be disposed over a small portion of an outside surface 214 of protective layer 206 at, for example, just the tips of the finger sheathes 302 and tip of a thumb sheathe 304. Liners/layers 202, 204, 206 and 208 may be disposed upon respective ones of liners/layers 202, 204, 206 and 208 in a variety of manners and designs and claimed subject matter is not limited in this regard.

FIG. 4 illustrates an example process 400 for making glove 100. In an example, at operation 406 intermediate liner 104 may be positioned on former 402. Moving to operation 408, protective layer 106 may be applied over a portion of intermediate liner 104 while disposed over former 402 according to various processes, such as those described with reference to FIG. 5 and/or FIG. 6. At operation 410, outer layer 108 may be applied over protective layer 106 while disposed over former 402 according to various processes, such as those described with reference to FIG. 5 and FIG. 6. At operation 412, intermediate liner 104, protective layer 106 and outer layer 108 may be removed from former 402 and disposed over innermost liner 102. At operation 414, innermost liner 102, intermediate liner 104, protective layer 106 and outer layer 108 may be coupled by a variety of methods, for example, by applying an adhesive 404 between innermost liner 102 and intermediate liner 104 and/or by a seam 406 joining innermost liner 102 and intermediate liner 104.

FIG. 5 illustrates an example of a process 500 for making a multi-layer glove. Process 500 will be described with reference to FIG. 1 and FIG. 4. In an example, process 500 begins at operation 502, where innermost liner 102 and/or intermediate liner 104 may be provided. For example, innermost liner 102 and intermediate liner 104 may each be sewn on an automatic loom. Innermost liner 102 may comprise a 10 gauge (10 GG(B)) terry cloth knit liner and intermediate liner 104 may comprise a 15 gauge (15 GG(B)) nylon knit liner. Both knit liners (102 and 104) may be sewn on the same automatic loom or on different looms.

At operation 506, innermost liner 102 may be brushed on outside surface 114 and/or inside surface 118 to knap the knitted material. Such knapping may be performed by an automated and/or manual method using a metal wire brush and/or other appropriate implement. Innermost liner 102 may be knapped on surface 118 first wherein surface 118 is facing outward and then inverted turning innermost liner 102 inside out to facilitate knapping of surface 114 thus making surface 118 an inside surface and surface 114 an outside surface. Knapping may provide protective thermal qualities to innermost liner 102. In one embodiment, innermost liner 102 is not knapped or roughed on any surface. In another example, both an inside surface and an outside surface may be brushed and thus knapped. If innermost liner 102 and/or intermediate liner 104 are identified as irregular, the irregular layer (102 or 104) may be removed from a production line.

At operation 508, intermediate liner 104 may be positioned onto a former (see former 402 in FIG. 4). Former 402 may be heated to impart elasticity to intermediate liner 104.

At operation 510, protective layer 106 may be applied to intermediate liner 104. In an example, former 402 with intermediate liner 104 positioned thereon may be dipped into a nitrile polymer to apply protective layer 106. Dipping may be performed vertically with fingertip portions 122 pointed downward. Dipping may be performed to any depth and at any desired angle and claimed subject matter is not limited in this regard. For example, former 402 may be dipped into the nitrile polymer to a depth sufficient to substantially cover intermediate liner 104 up to 100% of the lengthwise height 124 of glove 100. In another example, former 402 may be dipped into the nitrile polymer to a depth sufficient to substantially cover intermediate liner 104 less than 100% of the lengthwise height 124 of glove 100.

In an example, the nitrile polymer may provide puncture and/or water resistant/waterproof properties. Former 402 and intermediate liner 104 may be removed from the nitrile polymer compound and shaken. Shaking may substantially evenly distribute the nitrile polymer onto intermediate liner 104 to form protective layer 106. Protective layer 106 may be absorbed into a thickness 115 of intermediate liner 104 extending from an outside surface of intermediate liner 104 to an inside surface of intermediate liner 104 to a particular depth. In one example, protective layer 106 may be absorbed greater than 50% of a depth of intermediate liner 104.

At operation 512, former 402 with intermediate liner 104 and protective layer 106 positioned thereon may undergo a heated vulcanization process to cure protective layer 106. In one example, vulcanization may be performed in a vulcanization oven. Vulcanization may last for a period of about ten minutes at about 70° C. In an example, the vulcanization process may cure protective layer 106 to about 60% upon exit from the vulcanization oven. In other embodiments, different vulcanization processes may be possible and practical. Vulcanization may be performed in various vulcanization devices at various temperatures and for varying lengths of time and claimed subject matter is not limited in this regard.

At operation 514, outer layer 108 may be applied to protective layer 106. In an example, former 402 with intermediate liner 104 and protective layer 106 positioned thereon may be submerged and/or dipped into a liquid sandy nitrile polymer (SNP) to form outer layer 108. The SNP may improve wet and/or dry grip properties of glove 100. In one example, former 402 with intermediate liner 104 and protective layer 106 positioned thereon may be angled between vertical and horizontal to facilitate dipping of a palm and digits portion 126 of glove 100. In another example, former 402 with intermediate liner 104 and protective layer 106 positioned thereon may be angled at a substantially horizontal angle to facilitate dipping only a palm portion.

In an example, portion 126 may be dipped in the liquid SNP to a depth sufficient to submerge about ¾ of a width 128 (FIG. 1 b) of glove 100. Glove 100 may be dipped into the liquid SNP once or may be dipped into the liquid SNP two or more times.

At operation 512, former 402 with intermediate liner 104, protective layer 106 and outer layer 108 positioned thereon may undergo a heated vulcanization process to cure outer layer 108. In one example, vulcanization may be performed in a vulcanization oven. Vulcanization may last for a period of about ten minutes at about 90° C. In an example, the vulcanization process may cure outer layer 108 to about 80% upon exit from the vulcanization oven. In other embodiments, different vulcanization processes may be possible and practical. Vulcanization may be performed in various vulcanization devices at various temperatures and for varying lengths of time and claimed subject matter is not limited in this regard.

In one example, former 402 with the intermediate liner 104, protective layer 106 and outer layer 108 assembly positioned thereon may pass through a washing process submerged in water for a first period of time, such as the time to travel 30 meters along a production line. Former 402 with intermediate liner 104, protective layer 106 and outer layer 108 positioned thereon may then be sprayed by a shower of water for another period of time, such as the time to travel 30 meters along a production line.

In one example, former 402 with intermediate liner 104, protective layer 106 and outer layer 108 positioned thereon may dry for some period of time, for example 45 minutes with the aid of a fan. In one example, the intermediate liner 104, protective layer 106 and outer layer 108 assembly positioned thereon may be stripped from the former 402.

In one example, innermost liner 102 may be placed on a hot former to aide in its elasticity.

At operation 518, innermost liner and the intermediate liner 104, protective layer 106 and outer layer 108 assembly may be coupled to form glove 100. In an example, an adhesive 404 (FIG. 4) may be disposed on an outside surface 118 of innermost liner 102 for example on the ends of the five digits 122. In another embodiment, the adhesive may be applied to a larger portion of outside surface 118.

In an example, the intermediate liner 104, protective layer 106 and outer layer 108 assembly may be disposed over the top of innermost liner 102 which may be positioned on a former. The adhesive may dry/cure and bond innermost liner 102 to the intermediate liner 104, protective layer 106 and/or outer layer 108. The drying time may vary, for example based on the type of adhesive used. In one embodiment the adhesive may cure over a 30-minute period. Glove 100 may be stripped from the former and inspected for quality control. Glove 100 may be sewn together at cuff 406. Glove 100 may again be inspected for quality control.

FIG. 6 illustrates another example process 600 for making glove 100. Process 600 will be described with reference to FIG. 1. At operation 604, process 600 may start with 7 gauge acrylic thread woven through a lateral loom into a 7 GG(B) innermost liner 102. Innermost liner 102 may be of a predetermined size and seamless. Innermost liner 102 may be manufactured on automatic knitting machine containing many ‘crochet’ like needles programmed to produce the desired product. Various gauges are available to create different results, 7 gauge, or 7 cut, refers to 7 needles per inch which produces a bulkier, heavier glove liner in comparison to thinner, higher numbered gauges. Separately, a thinner 15 gauge nylon thread may be woven on a lateral loom into 15 GG(B) intermediate liner 104.

At operation 606, innermost liner 102 may be placed on a hand mold which may pass through a series of wire brushes to rough up the surface and knap brittle acrylic liner fibers. Innermost liner 102 may be removed from the hand mold and turned “inside out” to provide increased hand warmth through its now knapped inside surface. In an example, intermediate liner 104 may be placed over the outside surface 114 of innermost liner 102, and sewn at a cuff (see FIG. 4 element 406) combining liners 102 and 104 into a single two-ply knit glove liner.

At operation 608, glove formers may be attached by size to the assembly line. The formers may be ergonomically designed to fit a natural hand shape and reduce hand fatigue. The hand formers may then be loaded with the liner 102 and liner 104 assembly and inspected for exacting position.

At operation 610, innermost liner 102 and intermediate liner 104 assembly may be fully submerged directly into a liquid nitrile polymer compound to apply protective layer 106 to outside surface 116 of intermediate liner 104. In another example, innermost liner 102 and intermediate liner 104 assembly may be partially dipped in the liquid nitrile polymer, (e.g., dipping to 75% of lengthwise height 124) to coat a portion of an outside surface 116 of intermediate liner 106 and forming protective layer 106, In an example, the liquid nitrile polymer compound may seep into fibers of intermediate liner 104 which may result in improved thermoregulation properties and increased glove strength by providing resistance against snags, punctures and/or cuts. Without intermediate liner 104, protective layer 106 may seep into the knit fibers of the innermost liner 102 decreasing the amount of space between a user's hand and protective layer 106. A greater barrier space may increases air circulation thus aiding in thermoregulation.

At operation 612, the intermediate liner 102, intermediate liner 104 and protective layer 106 assembly may be vulcanized (or cured) in an oven.

At operation 614, outer layer 108 may be applied to outside surface 120 of protective layer 106. In an example, after curing, liners 102 and 104 and protective layer 106 may optionally be stripped from the hand former, inspected and positioned on a different hand former. Outer layer 108 may be applied to glove 100 shell, comprising liners 102 and 104 and protective layer 106, by submerging a portion or all of an outside surface of glove 100 shell in a liquid polymer formulated from sandy nitrile forming outer layer 108. Sandy nitrile may improve oil and wet grip of glove 100. Sandy nitrile has characteristics that increase abrasion resistance, as well as dry, wet and oily grip.

In an example, glove 100 shell may be fully dipped in the liquid polymer sandy nitrile. In another example, glove 100 shell may be partially dipped in the liquid polymer sandy nitrile (e.g., at ¾ depth and/or palm dipped) to coat a portion of an outside surface 120 of glove 100 shell and forming outer layer 108. In another example, the hand formers may continue on to a next dipping station where a coagulant may be applied to give glove 100 a textured finish for increased wet and dry grip.

In an example, process 600 may end here. In another example, process 600 may proceed to operation 616 where the innermost liner 102, intermediate liner 104, protective layer 106 and outer layer 108 assembly may be vulcanized (or cured) in an oven. At operation 618, glove 100 may be removed from the former ending process 600.

The process, system and apparatus described above may use dedicated processor systems, micro controllers, programmable logic devices, microprocessors, or the like, or any combination thereof, to perform some or all of the operations described herein. Some of the operations described above may be implemented in software and other operations may be implemented in hardware. One or more of the operations, processes, and/or methods described herein may be performed by an apparatus, a device, and/or a system substantially similar to those as described herein and with reference to the illustrated figures.

The processing device may execute instructions or “code” stored in memory. The memory may store data as well. The processing device may include, but may not be limited to, an analog processor, a digital processor, a microprocessor, a multi-core processor, a processor array, a network processor, or the like. The processing device may be part of an integrated control system or system manager, or may be provided as a portable electronic device configured to interface with a networked system either locally or remotely via wireless transmission.

The processor memory may be integrated together with the processing device, for example RAM or FLASH memory disposed within an integrated circuit microprocessor or the like, In other examples, the memory may comprise an independent device, such as an external disk drive, a storage array, a portable FLASH key fob, or the like. The memory and processing device may be operatively coupled together, or in communication with each other, for example by an I/O port, a network connection, or the like, and the processing device may read a file stored on the memory. Associated memory may be “read only” by design (ROM) by virtue of permission settings, or not. Other examples of memory may include, but may not be limited to, WORM, EPROM, EEPROM, FLASH, or the like, which may be implemented in solid state semiconductor devices. Other memories may comprise moving parts, such as a conventional rotating disk drive. All such memories may be “machine-readable” and may be readable by a processing device.

Operating instructions or commands may be implemented or embodied in tangible forms of stored computer software (also known as “computer program” or “code”). Programs, or code, may be stored in a digital memory and may be read by the processing device. “Computer-readable storage medium” (or alternatively, “machine-readable storage medium”) may include all of the foregoing types of memory, as well as new technologies of the future, as long as the memory may be capable of storing digital information in the nature of a computer program or other data, at least temporarily, and as long at the stored information may be “read” by an appropriate processing device. The term “computer-readable” may not be limited to the historical usage of “computer” to imply a complete mainframe, mini-computer, desktop or even laptop computer, Rather, “computer-readable” may comprise storage medium that may be readable by a processor, a processing device, or any computing system. Such media may be any available media that may be locally and/or remotely accessible by a computer or a processor, and may include volatile and non-volatile media, and removable and non-removable media, or the like, or any combination thereof.

A program stored in a computer-readable storage medium may comprise a computer program product. For example, a storage medium may be used as a convenient means to store or transport a computer program. For the sake of convenience, the operations may be described as various interconnected or coupled functional blocks or diagrams. However, there may be cases where these functional blocks or diagrams may be equivalently aggregated into a single logic device, program or operation with unclear boundaries.

Having described and illustrated the principles of examples, it should be apparent that the examples may be modified in arrangement and detail without departing from such principles. We claim all modifications and variation coming within the spirit and scope of the following claims. 

I claim:
 1. A glove, comprising: an innermost liner comprising a first knitted material of a first knit gauge; an intermediate liner disposed over a first outside surface of the innermost liner, the intermediate liner comprising a second knitted material of a second knit gauge wherein the first knit gauge is different from the second knit gauge; a protective layer disposed over a second outside surface of the intermediate liner; and an outer layer disposed over a third outside surface of the protective layer.
 2. The glove of claim 1, wherein an inside surface of the innermost liner is knapped.
 3. The glove of claim 1, wherein an inside surface and the first outside surface of the innermost liner is knapped.
 4. The glove of claim 1, wherein the innermost liner comprises nylon and the first knit gauge is 10 GG(B).
 5. The glove of claim 5, wherein intermediate liner comprises nylon and the second knit gauge is 15 GG(B).
 6. The glove of claim 1, wherein innermost liner comprises nylon and the first knit gauge is 7 GG(B).
 7. The glove of claim 6, wherein intermediate liner comprises nylon and the second knit gauge is 15 GG(B).
 8. The glove of claim 1, wherein the protective layer comprises a nitrile polymer.
 9. The glove of claim 8, wherein the nitrile polymer is absorbed through a width of the intermediate liner to less than a full width of the intermediate liner extending between an outside surface and an inner surface.
 10. The glove of claim 1, wherein the outer layer comprises a sandy nitrite polymer.
 11. The glove of claim 1, wherein the protective layer comprises a foamed nitrile polymer.
 12. A process for manufacturing a glove, comprising: providing an innermost glove liner and an intermediate glove liner, wherein the innermost glove liner comprises a first knitted material of a first gauge knit and the intermediate glove liner comprises a second knitted material of a second gauge knit; applying a protective layer to an first outside surface of the intermediate glove liner; vulcanizing an intermediate glove liner and protective layer assembly; applying an outer layer on a second outside surface of the protective layer; vulcanizing an outer layer, protective layer, and intermediate glove liner assembly; applying an adhesive to a third outside surface of the innermost glove liner; disposing the outer layer, the protective layer, and the intermediate glove liner assembly over the third outside surface of the innermost glove liner; and sewing the intermediate liner to the innermost liner at a cuff.
 13. The process of claim 12, further comprising: knapping a fourth outside surface of the innermost glove liner; and reversing the innermost glove liner to bring the fourth outside surface to an inside cavity of the innermost glove liner.
 14. The process of claim 13, further comprising knapping the third outside surface of the innermost glove.
 15. The process of claim 12, wherein the innermost glove liner is a heavier gauge knit than the intermediate glove liner.
 16. The process of claim 12, wherein the innermost glove liner is a 10 gauge knit and the intermediate glove liner is a 15 gauge knit.
 17. The process of claim 12, wherein the protective layer comprises a nitrile polymer.
 18. The process of claim 17, wherein the nitrile polymer is absorbed through a width of the intermediate liner to less than a full width of the intermediate liner extending between an outside surface and an inner surface.
 19. The process of claim 12, wherein the outer layer comprises a sandy nitrile polymer.
 20. A process for manufacturing a glove, comprising: providing an innermost glove liner and an intermediate glove liner, wherein the innermost glove liner is a first gauge knit and the intermediate glove liner is a second gauge knit, wherein the first gauge knit is heavier than the second gauge knit; coupling the innermost glove liner and the intermediate glove liner; applying a protective layer to a first outside surface of the intermediate glove liner, the protective layer comprising an unadulterated smooth nitrile polymer; vulcanizing a protective layer, intermediate glove liner, and innermost glove liner assembly; applying an outer layer on a second outside surface of the protective layer, the outer layer comprising a sandy nitrile polymer; and vulcanizing an outer layer, protective layer, intermediate glove liner, and innermost glove liner assembly. 